Battery parts having retaining and sealing features and associated methods of manufacture and use

ABSTRACT

Battery parts having retaining and sealing features and associated assemblies and methods are disclosed herein. In one embodiment, a battery part includes a base portion that is configured to be embedded in battery container material of a corresponding battery container. The battery part and base portion include several torque resisting features and gripping features that resist torsional or twist loads that are applied to the battery part after it has been joined to the battery container. For example, the base portion can include several internal and external torque resisting features and gripping features that are configured to resist twisting or loosening of the battery part with reference to the battery container material, as well as prevent or inhibit fluid leakage from the battery container.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation of U.S. patent applicationSer. No. 14/325,273 filed Jul. 7, 2014, which is a Continuation of U.S.patent application Ser. No. 13/927,044 filed Jun. 25, 2013, now U.S.Pat. No. 8.802,282, which is a Continuation of U.S. patent applicationSer. No. 12/771,714 filed Apr. 30, 2010, now U.S. Pat. No. 8,497,036,which claims priority to U.S. Provisional Patent Application No.61/174,344, titled “Battery Parts Having Retaining and Sealing Featuresand Associated Methods of Manufacture and Use,” filed Apr. 30, 2009, allof which are incorporated herein in their entirety by reference.

TECHNICAL FIELD

The following disclosure relates generally to battery parts and, moreparticularly, to battery terminals, battery terminal bushings, and thelike.

BACKGROUND

Battery terminals are typically cold formed or die cast from lead orlead alloys. In a conventional battery, the terminals protrude from acasing or container which carries electrolyte. The container istypically formed from a moldable thermoplastic resin, such aspolypropylene. During manufacture of the container, the resin flowsaround the base of the terminals so that the resin will secure theterminals in place once it hardens. After a terminal has been secured, alead anode can be inserted into a central hole in the terminal andmelted to fill the hole and form a mechanical and electrical connectionto a battery grid positioned within the container.

Battery terminals can include annular acid rings that extend around thebase of the terminal to provide an extended interface between the baseof the terminal and the adjacent container material. This interface canprovide a torturous path or “labyrinth seal” that inhibits or preventselectrolyte from escaping the battery container. Various types ofterminal seals, and methods for making such seals are disclosed in U.S.Pat. No. 7,338,539, titled “Die Cast Battery Terminal and Method ofMaking Same,” filed Mar. 4, 2004, and US Patent Application PublicationNo. 2005/0147882, titled “Battery Part,” filed Dec. 3, 2004, each ofwhich are incorporated into the present application in their entiretiesby reference. Conventional battery terminals may become loose in thecontainer wall if subjected to repeated or excessive twisting ortorsional loads, Additionally, shrinkage of the battery container mayalso contribute to loosening of conventional terminals over time.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front view and FIG. 1B is a side view of a battery partconfigured in accordance with an embodiment of the disclosure,

FIG. 1C is an enlarged detail view of a portion of the battery partillustrated in FIGS. 1A and 1B.

FIG. 2A is a top end view and FIG. 2B is a bottom end view of thebattery part illustrated in FIGS. 1A and 1B.

FIG. 3A is a partial side cross-sectional view of the battery partillustrated in FIGS. 1A-2B, taken substantially along line 3A-3A in FIG.2A.

FIG. 3B is a partial isometric bottom end view of the battery partillustrated in FIGS. 1A-3A.

FIG. 4A is a partial cut-away isometric side view of a battery assemblyconfigured in accordance with an embodiment of the disclosure,

FIG. 4B is a partially exploded view, and FIG. 4C is a fully explodedview of the battery assembly illustrated in FIG. 4A.

FIG. 5 is a partial side cross-sectional view of a battery assemblyconfigured in accordance with another embodiment of the disclosure.

FIG. 6A is a front view of a battery part configured in accordance withyet another embodiment of the disclosure.

FIG. 6B is a partial side cross-sectional view of the battery part ofFIG. 6A.

FIG. 6C is a front view of the battery part of FIG. 6A before formingcertain features of the battery part illustrated in FIG. 6A.

FIG. 6D is a partial side cross-sectional view of the battery part ofFIG. 6C.

FIG. 7 is a partial side cross-sectional view of a battery assemblyconfigured in accordance with another embodiment of the disclosure.

FIG. 8A is a side cross-sectional view of a die assembly configured inaccordance with yet another embodiment of the disclosure.

FIG. 8B is an enlarged detail view of a portion of the assembly of FIG.8A.

FIG. 8C is a side cross-sectional view of the assembly of FIG. 8A at adifferent stage of a forming process.

FIG. 8D is an enlarged detail view of a portion of the assembly of FIG.8C.

DETAILED DESCRIPTION

The following disclosure describes various embodiments of battery parts,such as battery terminals or bushings and the like, and associatedassemblies and methods of manufacture and use. In one embodiment, abattery terminal configured in accordance with the present disclosureincludes a body having a base portion that is configured to be embeddedin battery container material when the corresponding battery containeris formed. The base portion includes several torque resisting featuresand gripping features that resist torsional or twist loads that areapplied to the battery terminal after it has been joined to the batterycontainer. In one embodiment, for example, a through hole extendsthrough the battery terminal, and the base portion includes a texturedor knurled surface at an inner periphery portion of the base portion.The textured surface can include a plurality of alternating grooves andprotrusions in a beveled interior surface of the base portion, with thegrooves positioned in a helical or angled pattern. In certainembodiments, the grooves can include a first group of grooves angled orextending in a first direction and a second group of grooves angled orextending in a second direction opposite the first direction, In stillfurther embodiments, battery terminals configured in accordance with thepresent disclosure can include torque resisting features including, forexample, flanges, lips, and/or other projections having polygonalshapes, as well as channels, grooves, indentations, serrations, teeth,etc. configured to engage the battery container material.

Certain details are set forth in the following description and in FIGS.1-8D to provide a thorough understanding of various embodiments of thedisclosure. Other details describing well-known structures and systemsoften associated with battery parts (e.g., lead and/or lead alloybattery parts, moldable battery containers, etc.), and methods forforming such parts (e.g., forming, casting, injection molding, etc.), aswell as other battery parts and assemblies, are not set forth in thefollowing disclosure to avoid unnecessarily obscuring the description ofthe various embodiments of the disclosure.

Many of the details, dimensions, angles and/or other portions shown inthe Figures are merely illustrative of particular embodiments of thedisclosure. Accordingly, other embodiments can have other details,dimensions, angles and/or portions without departing from the spirit orscope of the present disclosure. In addition, further embodiments of thedisclosure may be practiced without several of the details describedbelow, while still other embodiments of the disclosure may be practicedwith additional details and/or portions.

In the Figures, identical reference numbers identify identical or atleast generally similar elements. To facilitate the discussion of anyparticular element, the most significant digit or digits of anyreference number refers to the Figure in which that element is firstintroduced. For example, element 110 is first introduced and discussedwith reference to FIG. 1.

FIG. 1A is a front view and FIG. 1B is a side view of a battery part 100configured in accordance with an embodiment of the disclosure. Referringto FIGS. 1A and 1B together, in the illustrated embodiment the batterypart 100 comprises a battery terminal or terminal bushing. The batterypart 100 can be formed from lead, lead alloy, and/or other suitablematerials by forming (e.g., cold-forming, cold-forming with a segmentedmold, hot-forming, roll-forming, stamping, etc.), casting (e.g., diecasting), forging, machining, and/or other suitable methods known in theart. In one aspect of this embodiment, the battery part 100 includes aprojecting portion or lug portion 104 that extends from a base portion103. The battery part 100 can also include a passage or through-hole 106extending through the battery part 100 from a first end portion 101 to asecond end portion 102.

In another aspect of this embodiment, the base portion 103 includes afirst torque-resisting feature 105 spaced apart from a secondtorque-resisting feature 107 by an annular channel 111. In theillustrated embodiment, the first torque-resisting feature 105 includesa first flange 112 and the second torque-resisting feature 107 includesa second flange 114. Each of the first and second flanges 112 and 114projects from the base portion 103 and extends around the battery part100. In other embodiments, however, battery parts configured inaccordance with the present disclosure can include one or more flangesthat extend only partially around the base portion 103 of the batterypart 100.

Each of the first and second flanges 112 and 114 is configured to resisttorsional or twist loads that are applied to the battery part 100 afterit has been joined to a battery container (as described in more detailbelow). More particularly, in the illustrated embodiment the firstflange 112 has a polygonal shape (e.g., a dodecagonal shape) with aplurality of flat, or at least generally flat, side portions 113 a-l.Similarly, the second flange 114 also has a polygonal shape (e.g., adodecagonal shape) with a plurality of flat, or at least generally flat,side portions 115 a-l. Accordingly, the first and second flange portions112 and 114 of the illustrated embodiment have non-circular peripheriesthat are configured to enhance the ability of the battery part 100 toresist torsional loads during use.

In other embodiments, however, battery parts configured in accordancewith the present disclosure can include more or fewer flanges (e.g.,torque flanges) or flange portions having other shapes, including those,for example, disclosed in International Patent Application No.PCT/US2008/064161, titled “Battery Parts and Associated Methods ofManufacture and Use,” filed May 19, 2008, which is incorporated hereinby reference in its entirety. These flange or flange portion shapes caninclude, for example, polygons (e.g., octagons, hexagons, pentagons,squares, rectangles, triangles, etc.), rectilinear shapes, curvilinearshapes, non-circular shapes, circular or partially-circular shapes,symmetrical shapes, non-symmetrical shapes, irregular shapes, saw-toothshapes, sun-burst shapes, star patterns, cross-shapes, peripheral teeth,serrations, flat surface portions, angular surface portions, concavesurface portions, convex surface portions, etc. Battery parts configuredin accordance with the present disclosure can also include othertorque-resisting features such as other types of flanges, portions offlanges, lips, protrusions, and/or other projections that extend around,or at least partially around, the battery part 100 with non-circularperipheries. Such torque-resisting features can also include recessedportions or indentations in the battery part 100. In addition, invarious embodiments the first flange 112 can have a different shape thanthe second flange 114. Accordingly, the present disclosure is notlimited to dodecagonal-shaped or polygonal-shaped torque resistingflanges, but extends to other flanges, flange portions and other torqueresisting features having other shapes. Additionally, other embodimentsof the disclosure can include battery terminals, terminal bushings, andother battery parts having configurations that may differ from thatillustrated in FIGS. 1A and 1B. For example, battery terminals and otherbattery parts having lugs and/or other features that may differ fromthat shown in FIGS. 1A and 1B can also include aspects of the presentdisclosure disclosed herein.

According to another feature of the embodiment illustrated in FIGS. 1Aand 1B, the battery part 100 includes other torque resisting features inaddition to the shapes of the first flange 112 and the second flange114. For example, the second flange 114 includes a serrated ortooth-like edge portion facing the first flange 112. More specifically,the second flange 114 includes a plurality of recesses or grooves 117a-n partially extending through the second flange 114. For example, asshown in FIG. 1C, which is an enlarged detail view of a portion of thebattery part 100 of FIG. 1A, the illustrated groove 117 a has an upsidedown U-shaped configuration with a slanted or beveled sidewall 125extending from the first side portion 115 a toward the channel 111.Referring again to FIGS. 1A and 1B, in the illustrated embodiment and asalso described below with reference to FIG. 2A, the grooves 117 a-nextend through the second flange 114 in the same direction and at leastgenerally parallel to one another. In other embodiments, however, thegrooves 117 a-n can extend in other directions including, for example,radially inwardly towards the base portion 103. The grooves 117 a-n areconfigured to engage or otherwise grip the battery container materialthat is molded around the second flange 114 to at least partiallyprevent the battery part 100 from twisting or otherwise moving in thebattery container.

In a further aspect of this embodiment, the base portion 103 includes asealing portion 109 positioned between the first flange 112 and thesecond flange 114. In the illustrated embodiment, the sealing portion109 includes the annular channel 111 that extends around the baseportion 103. The sealing portion 109, in combination with the first andsecond flanges 112 and 114, can interface with the battery containermaterial that is molded around them to form a torturous path-type sealto inhibit or prevent electrolyte or acid from escaping the batterycontainer. In other embodiments, battery parts configured in accordancewith the present disclosure can include other types of sealing portions,sealing rings, and/or other sealing features that extend around, or atleast partially around the base portion 103.

According to yet another feature of this embodiment, the battery part100 includes a stepped cavity that forms the through-hole 106 extendingthrough the base and lug portions 103 and 104. More specifically, in theillustrated embodiment, a first cavity 121 extends from the base portion103 partially into the lug portion 104. The first cavity 121 has atapered cylindrical or generally frustoconical shape that is axiallyaligned with a second cavity 123 in the lug portion 104. The secondcavity 123 extends from the first cavity 121 through the remainder ofthe lug portion 104 towards the second end portion 102. The secondcavity 123 also has a tapered cylindrical or generally frustoconicalshape with a tapering cross-sectional dimension or diameter that issmaller than a corresponding tapering diameter of the first cavity 121.The through-hole 106 includes a stepped portion or shoulder 127 at theinterface between the first and second cavities 121 and 123. Asexplained in detail below, when the battery part 100 is at leastpartially embedded in the battery container material, the batterycontainer material can flow into the battery part 100 adjacent to aportion of the first cavity 121 up to the shoulder 127.

In the illustrated embodiment, the base portion 103 also includes aplurality of gripping features 130 (shown in broken lines in FIGS. 1Aand 1B) forming a textured or knurled surface at the inner peripheryportion of the base portion 103. As described in more detail below, thegripping features 130 are configured to grip or otherwise engage thematerial of the battery container and/or resist torque when the batterypart 100 is embedded in a battery container.

FIG. 2A is a top end view and FIG. 2B is a bottom end view of thebattery part 100 illustrated in FIGS. 1A-1C. Referring first to FIG. 2A,as shown in the illustrated embodiment, the grooves 117 a-n (shown inbroken lines) in the second flange 114 extend in the same direction andare at least generally parallel to one another. In this manner, thedepth of each groove 117 into the second flange 114 towards the baseportion 103 (e.g., in a direction generally perpendicular to alongitudinal axis of the battery part 100) varies around the peripheryof the second flange 114. As noted above, however, in other embodiments,the grooves 117 can extend in other directions, including, for exampleradially outward from the battery part 100. In addition, more or lessgrooves 117 than those illustrated in FIG. 2A can extend into the secondflange 114.

Referring next to FIG. 2B, in the illustrated embodiment the grippingfeatures 130 include a plurality of teeth or protrusions positionedbetween adjacent grooves, notches, or channels that form a textured orknurled surface 231 around the inner periphery portion of the baseportion 103 (e.g., at the inner diameter of the lower portion of thefirst cavity 121). More specifically, the gripping features 130 includea first group 232 of alternating grooves 234 and protrusions 235extending around at least approximately 180 degrees of the innerperiphery of the base portion 103. The gripping features 130 alsoinclude a second group 236 of alternating grooves 238 and protrusions239 extending around at least approximately the remaining 180 degrees ofthe inner periphery of the base portion 103. According to one feature ofthe illustrated embodiment, the grooves 234 in the first group 232 aregenerally the same as the grooves 238 in the second group 236, with theexception that the grooves 238 in the second group are arranged in ahelical pattern that is opposite a helical pattern of the grooves 234 inthe first group 232 (i.e., the grooves 234 and 238 of the first andsecond groups 232 and 236 are angled or slanted in opposite directions).More specifically, each of the grooves 234 and 238 can be formed in theshape of a segment of a helix (e.g., generally similar to the pattern ofteeth in a helical gear), with the grooves 234 in the first group 232 atan angle that is opposite or otherwise different from the grooves 238 inthe second group 236. In other embodiments, however, all of the grooves234 and 238 can extend in generally the same direction or pattern (e.g.,clockwise, counterclockwise, etc.), or different portions or groups ofthe grooves 234 and 238 can extend in different directions. Moreover, instill further embodiments the gripping features 130 (e.g., the grooves234 and 238 and the protrusions 235 and 239) can be straight, ratherthan arranged in a helical pattern around the inner periphery of thebase portion 103. Further aspects of the gripping features 130 aredescribed in detail below with reference to FIGS. 3A and 3B.

FIG. 3A is a partial side cross-sectional view of the battery part 100illustrated in FIGS. 1A-2B, taken substantially along line 3A-3A in FIG.2A. This view illustrates the gripping features 130 that form thetextured (e.g., knurled, serrated, notched, saw-tooth, indented, etc.)surface around an inner periphery 331 of the base portion 103. Forexample, FIG. 3A illustrates the second group 236 of grooves 238 andprotrusions 239 that are formed in an inner surface of the first cavity121. Moreover, the inner periphery 331 of the base portion 103 furtherincludes an inclined or beveled face 339 extending radially outward froman inner surface 337 of the first cavity 121 towards a bottom surface340 of the battery part 100. Each groove 238 extends through a portionof the inner surface 337 and the beveled surface 339 and is angled orslanted at an angle B relative to a longitudinal axis L of the batterypart 100. In certain embodiments, the angle B can be from about 15degrees to about 35 degrees, or about 25 degrees. In other embodimentsthe angle B can have other dimensions.

Although the illustrated gripping features 130 are described herein asalternating channels or grooves 236 and 238 and correspondingprotrusions 235 and 239, one skilled in the art will appreciate that thegripping features can include any forms or shapes that collectively formthe textured surface at the inner periphery 331 of the base portion 103.For example, the gripping features 130 can include grooves, channels,recesses, holes, indentations, depressions, notches, teeth, serrations,bumps, etc., to create the textured beveled face 339 and/or innerperiphery 331. Moreover, the gripping features 130 can be arranged inany pattern, including, for example, non-helical patterns, symmetricalpatterns, non-symmetrical patterns, etc,

As also shown in FIG. 3A, the through-hole 106 has the largestcross-sectional dimension or diameter at the bottom surface 340, and thediameter of the through-hole 106 tapers or decreases along the beveledface 339, and further along the inner surface 337 of the first cavity121 and an inner surface 335 of the second cavity 123 towards the secondend portion 102 of the battery part 100. According to another feature ofthis embodiment, the battery part 100 includes an offset between thesizes of the first cavity 121 and the second cavity 123. As describedabove, for example, the battery part 100 includes the shoulder 127 atthe interface between the first cavity 121 and the second cavity 123.Accordingly, an extension line 342 (shown in broken lines) extendingfrom the inner surface 335 of the second cavity 123 is spaced apart fromthe inner surface 337 of the first cavity 121 by a width W. As describedin detail below, when the battery part 100 is encased in batterycontainer material with a mold part or plug positioned in the batterypart 100, the battery container material can flow into a portion of thefirst cavity 121 to at least partially fill-in the width W between theinner surface 337 of the first cavity 121 and the extension line 342 upto the shoulder 127. Moreover, and as also described below, the grippingfeatures 130 can at least partially facilitate the flow of the batterycontainer material into the first cavity 121, as well as grip orotherwise engage the battery container material to prevent the batterypart 100 from twisting or moving in the battery container.

FIG. 3B is a partial isometric end view of the battery part 100 furtherillustrating several of the features described above. For example, asshown in FIG. 3B, the battery part 100 includes the gripping features130 at the inner diameter or inner periphery 331 of the base portion103. More specifically, the grooves 234 and 238, and correspondingprotrusions 235 and 239, extend from the bottom surface 340 along thebeveled surface 339 to the inner surface 337 of the first cavity 121.Accordingly, the gripping features 130 form the textured or knurledinner periphery 331 of the battery part 100. FIG. 3B also illustratesthe shoulder 127 at the interface of the first cavity 121 and the secondcavity 123.

FIGS. 4A-4C are a series of views illustrating several features of abattery assembly 440 configured in accordance with an embodiment of thedisclosure. Referring first to FIG. 4A, FIG. 4A is a partial cut-awayisometric side view of the battery assembly 440 including the batterypart 100 (i.e., the battery part 100 described above with reference toFIGS. 1A-3B) fixedly attached to a battery casing or container 442 sothat the lug portion 104 is exposed and accessible. The batterycontainer 442 can be formed from a moldable material 448, such aspolypropylene, polyethylene, other plastics, thermoplastic resins,and/or other suitable materials known in the art. During manufacture ofthe battery assembly 440, molten container material 448 can be flowedaround the base portion 103 of the battery part 100 so that the firstflange 112 is embedded in the container material 448, and the secondflange 114 is embedded in the container material 448 adjacent to anouter surface portion 444. The container material 448 also molds aroundthe base portion 103 to create a seal that can prevent or at leastinhibit liquid (e.g., electrolyte, acid, water, etc.) from escaping thebattery container 442. Moreover, the container material 448 also flowsand/or molds around the torque resisting features and characteristics ofthe base portion 103 described above to prevent the battery part 100from twisting or moving in the battery container 442 when an externalforce is applied.

According to another feature of this embodiment, and as noted above, thecontainer material 448 can also flow and mold around a portion of theinterior of the battery part 100. More specifically, at this stage inthe manufacturing, the battery assembly 400 includes a mold plug or diemember 450 received in the through-hole 106 of the battery part 100. Thedie member 450 substantially fills the second cavity 123 (FIGS. 1A and1B) and contacts the inner surface 106 of the lug portion 104, however,there is a gap in the first cavity 121 between the die member 450 andthe inner surface 337 of first cavity 121 of the battery part 100 (see,e.g., FIG. 3A illustrating the gap G having a width W, and FIG. 5).Accordingly, the container material 448 can flow into the first cavity121 and at least partially fill the first cavity 121 between the diemember 450 and the battery part 100. After the battery part 100 has beensecured to the battery container 442 as illustrated in FIG. 4A, the diemember 450 is removed from the through-hole 106. The through-hole 106can then be filled with molten lead or other suitable material to form amechanical and electrical connection between the battery part 100 and abattery grid (not shown) within the battery container 442.

FIG. 4B is a partially exploded view, and FIG. 4C is a fully explodedview of the battery assembly 400. The battery assembly 400 is shown inthe partially exploded and exploded views for purposes of illustratingseveral features of the engagement or interface of the containermaterial 448 with the battery part 100. For example, referring to FIGS.4B and 4C together, the container material 448 includes a wall portion460 that extends into the battery part 100 (and surrounds the die member450 when the die member is positioned in the battery part 100) adjacentto the inner surface 337 of the first cavity 121 (FIG. 3A). The wallportion 460 is formed when the container material flows into the gapbetween the inner surface 337 of the first cavity 121 and the die member450. In certain embodiments, the wall portion 460 has a height thatcorresponds to the height of the shoulder 127 at the interface betweenthe first and second cavities 121 and 123 of the battery part 100 (FIG.3A). In other embodiments, the container material may not completelyfill the gap between the battery part 100 and the die member 450.

FIG. 5 is a partial side cross-sectional view of a completed batteryassembly 570 configured in accordance with another embodiment of thedisclosure. In the illustrated embodiment, the battery part 100 isfixedly attached to the moldable material 448 of the battery container442. The battery assembly 570 also includes a lead anode or conductor572 that is mechanically and electrically connected to the battery part100. More specifically, the conductor 572 fills the through-hole 106 andcan be connected to a battery grid (not shown) positioned within thebattery container 442.

According to one aspect of this embodiment, an exterior surface 574 ofthe conductor 572 is spaced apart from the inner surface 337 of thefirst cavity 121 by a gap having a width W. However, as described abovewith reference to FIGS. 4A-4C, the wall portion 460 of the mold material448 is positioned adjacent to the inner surface 337 of the first cavity121 to fill the gap between the conductor 570 and the battery part 100.In certain embodiments and as shown in FIG. 5, the wall portion 460completely fills the gap and extends to the shoulder 127 of the batterypart. In other embodiments, however, the mold material 448 may onlypartially fill the gap between the conductor 572 and the battery part100.

One advantage of the embodiments described above with reference to FIGS.1A-5 is that the gripping features 130 forming the textured surface atthe inner periphery portion of the base portion 103 may advantageouslyreduce the amount of lead required to make the battery part 100.Moreover, the grooves 234 and 238 of the gripping features 130 alsoadvantageously facilitate the flow of the battery container material 448adjacent to the inner surface 337 of the first cavity 121 when thebattery part 100 is embedded in the battery container 442. In addition,the gripping features 130 may also engage the battery container material448 and at least partially prevent the battery part 100 from twisting(e.g., in a clockwise direction and/or a counter clockwise direction) inthe battery container 442 and/or from otherwise loosening or moving inthe battery container 442.

FIG. 6A is a front view of a battery part 600 configured in accordancewith another embodiment of the disclosure. FIG. 6B is a partial sidecross-sectional view of the battery part 600 of FIG. 6A. Referring toFIGS. 6A and 6B together, the battery part 600 includes several featuresthat are at least generally similar in structure and function to thecorresponding features of the battery parts described above withreference to FIGS. 1A-5. For example, the battery part 600 illustratedin FIGS. 6A and 6B includes a projecting portion or lug portion 604extending from a base portion 603, and a through-hole 606 extendinglongitudinally through the battery part 600. The base portion 603includes a first torque-resisting feature 605 spaced apart from a secondtorque-resisting feature 607 by an annular channel 611. The firsttorque-resisting feature 605 includes a first flange 612 and the secondtorque-resisting feature 607 includes a second flange 614. The firstflange 612 can have a polygonal shape and can include a plurality offlat, or at least generally flat, side portions 615. The second flange614 can include a plurality of recesses or grooves 617 extending atleast partially through the second flange 614. The base portion 603 alsoincludes a plurality of gripping features 630 (shown in broken lines inFIG. 6A) forming a textured or knurled surface at the inner peripheryportion of the base portion 603. The gripping features 630, incombination with the first and second torque resisting features 605 and607, are configured to grip or otherwise engage the material of abattery container when the battery part 600 is embedded in the batterycontainer.

The base portion 603 further includes a first sealing portion 609between the first flange 612 and the second flange 614. The firstsealing portion 609 can include the annular channel 611 extending aroundthe base portion 603. The first sealing portion 609, in combination withthe first and second flanges 612 and 614, can form an interface with thebattery container material that is molded around them to form atorturous path-type seal to inhibit or prevent electrolyte, acid, and/orother fluids from escaping the battery container.

In one aspect of the illustrated embodiment, the battery part 600includes a first engaging portion 676 that is also configured to form aseal with the battery container material and/or engage the batterycontainer material to prevent the battery part 600 from moving orloosening in the battery container. More specifically, and asillustrated in detail in FIG. 6B, the second seal portion 676 includesan annular groove 678 extending between gripping projections or sealingmembers 677 (identified individually as a first gripping projection orsealing member 677 a and a second gripping projection or sealing member677 b). In the illustrated embodiment, the sealing members 677 and thegroove 678 extend around a periphery of the base portion 603 above thesecond flange 614. Each of the sealing members 677 includes a flange orannular lip with an edge portion 679 (identified individually as a firstedge portion 679 a and a second edge portion 679 b) extending outwardlyfrom the base portion 603. The sealing members 677 form a bifurcatedportion of the second flange 614 with the edge portions 679 extendingradially outwardly from the base portion 603. In certain embodiments,and as explained in detail below, each edge portion 679 is at leastpartially deformed (e.g., crimped) or otherwise deflected or directedtowards the opposing edge portion 679. For example, the first engagingportion 676 can include a first dimension D₁ between the edge portions679 of the sealing members 677 that is less than a second dimension D₂of the groove 678, the second dimension D₂ spanning across the largestopening or dimension in the groove 678. Due to the deformed or crimpededge portions 679, the inner surfaces of the sealing members 677 facingthe groove 678 are at least partially curved and non-planar. The firstsealing member 677 a also includes a stepped or shoulder portion 680that is adjacent to a lateral face 681 extending radially away from thelug portion 604.

According to yet another feature of the illustrated embodiment, thebattery part 600 includes a second engaging portion 682 at a stepped orshoulder portion 627 of the through-hole 606. More specifically, thethrough-hole 606 includes a first cavity 621 extending from the baseportion 603 partially into the lug portion 604. The first cavity 621 hasa tapered cylindrical or generally frustoconical shape that is axiallyaligned with a second cavity 623 in the lug portion 604. The secondcavity 623 extends from the first cavity 621 through the remainder ofthe lug portion 604. The second cavity 623 also has a taperedcylindrical or generally frustoconical shape with a taperingcross-sectional dimension or diameter that is smaller than acorresponding tapering diameter of the first cavity 621. An extensionline 642 (shown in broken lines) extending from an inner surface 635 ofthe second cavity 623 is spaced apart from an inner surface 637 of thefirst cavity 121 by a first width W₁.

The shoulder portion 627 of the through-hole 606 is located at theinterface between the first cavity 621 and the second cavity 623. At theshoulder portion 627, the second engaging portion 682 includes a web,flange, lip, or projection 683 extending downwardly from the innersurface 635 of the second cavity 623 into the first cavity 621. Theprojection 683 is spaced apart from the inner surface 637 of the firstcavity 621 and defines a pocket or recess 684 therebetween. In theillustrated embodiment the projection 683 is deformed (e.g., crimped) orotherwise deflected or directed towards the inner surface 637 of thefirst cavity 621 such that an end portion of the projection 683 isspaced apart from the inner surface 637 of the first cavity 621 by asecond width W₂ that is less than the first width W₁. As described indetail below, when the battery part 600 is encased in battery containermaterial with a mold part or plug positioned in the cavity 606 of thebattery part 600, the battery container material can flow into a portionof the first cavity 621 to at least partially fill the first width W₁between the inner surface 637 of the first cavity 621 and the extensionline 642. When the battery part 600 is embedded in the battery containermaterial, the second engaging portion 682, including the projection 683forming the pocket 684 at the shoulder portion 627, can at leastpartially engage and/or retain the battery container material to preventthe battery part 600 from twisting or moving in the battery container.The second engaging portion 682 can also prevent a fluid from leakingfrom the battery container.

FIG. 6C is a front view of the battery part 600 of FIG. 6A, illustratingthe battery part 600 before forming or completing certain features ofthe first engaging portion 676 and the second engaging portion 682. FIG.6D is a partial side cross-sectional view of the battery part of FIG.6C. Referring to FIGS. 6C and 6D together, at this stage the edgeportions 679 of the corresponding sealing members 677 have not yet beendeformed or directed towards one another. More specifically, and asshown in FIG. 6D, a third dimension D₃ between the edge portions 679 isgreater than the second dimension D₂ of the groove 678 before thesealing members 677 are deformed. In addition, at the stage illustratedin FIGS. 6C and 6D, the projection 683 of the second engaging portion682 has not yet been deformed or directed towards the inner surface ofthe first cavity 621. Rather, the projection 683 is generally parallelwith the inner surface of the second cavity 623. The process ofdeforming or completing these features of the first and second engagingportions 676 and 682 is described in detail below with reference toFIGS. 9A-9D.

FIG. 7 is a partial side cross-sectional view of a completed batteryassembly 770 configured in accordance with an embodiment of thedisclosure. In the illustrated embodiment, the battery assembly 770includes the battery part 600 described above with reference to FIGS. 6Aand 6B, which is fixedly attached to moldable material 748 of a batterycontainer 742. The lateral face 681 of the base portion 603 is at leastgenerally aligned with an exterior surface 749 of the battery container742. The battery assembly 770 further includes a lead anode or conductor772 that is mechanically and electrically connected to the battery part600. For example, the conductor 772 can completely fill the secondcavity 623 of the through-hole 606 and can be connected to a batterygrid (not shown) positioned within the battery container 742. Moreover,an exterior surface 774 of the conductor 772 is spaced apart from theinner surface 637 of the first cavity 621 by a gap having the firstwidth W₁. A wall portion 760 of the mold material 748 is molded adjacentto the inner surface 637 of the first cavity 621 to fill the gap betweenthe conductor 770 and the battery part 600. In the illustratedembodiment, the wall portion 760 extends to the shoulder portion 627 ofthe battery part 600.

In the illustrated embodiment, the first engaging portion 676 and thesecond engaging portion 682 engage or otherwise contact the moldmaterial 748 to retain and seal the battery part 600 in the batterycontainer 742. Accordingly, the first engaging portion 676 and thesecond engaging portion 682 at least partially prevent the battery part600 from pulling out of the battery container 742 and/or prevent fluidfrom leaking from the battery container 742 at the interface between thebattery container 742 and the battery part 600. More specifically, withreference to the first engaging portion 676, the crimped or angled edgeportions 679 of the sealing members 677 retain the mold material 748 inthe groove 678 between the sealing members 677. For example, as the moldmaterial 748 solidifies around the base portion 603 of the battery part600, the sealing members 677 retain the mold material 748 in the groove678 and at least partially prevent the mold material 748 from shrinkingor retracting away from the base portion 603. Similarly, the projection683 of the second engaging portion 682 also at least partially engagesand/or retains the mold material 748 in the recess 684 and adjacent tothe inner surface 637 of the first cavity 621 of the battery part 600.The projection 683 accordingly at least partially prevents the moldmaterial 748 from shrinking or retracting out of the pocket 684.

FIG. 8A is a cross-sectional side view of an assembly 885 for forming abattery part in accordance with an embodiment of the disclosure. FIG. 8Bis an enlarged detail view of a portion of the assembly 885 of FIG. 8A.Referring to FIGS. 8A and 8B together, in the illustrated embodiment theassembly 885 is a forming die assembly that is used to crimp or deformthe engaging features of the battery part 600 described above withreference to FIGS. 6A-7. In FIGS. 8A and 8B, the battery part 600 isshown in the assembly 885 at the stage of FIGS. 6C and 6D before theengaging members 677 are crimped or deformed. The assembly 885 includesa first block or die member 892 and a second block or die member 886.The first and second die members 892 and 886 are movable relative toeach another in the directions indicated by arrow A (e.g., towards andaway from each other). The first die member 892 includes a cavity 893that has a first shaping or deforming surface 894. The second die member886 has a corresponding second shaping or deforming surface 887. Thefirst deforming surface 894 is aligned with the second deforming surface887. Moreover, the first and second deforming surfaces 894 and 887 arealso aligned with the corresponding edge portions 679 of the first andsecond sealing members 677 a and 677 b of the battery part 600. As shownin FIGS. 8A and 8B, at this stage of the processing, the first diemember 892 is spaced apart from the second die member 886 by a gap G.

The second die member 886 receives a sleeve 888, which in turn receivesa plunger or core 889. The core 889 includes an end portion 890 having athird crimping or deforming surface 891. The third deforming surface 891can be a tapered or angled shoulder of the end portion 890 of the core889 to crimp or deform the extension 683 of the second engaging portion682. The core 889 is movable relative to the first and second diemembers 892 and 886 in the directions indicated by arrow A.

To form the crimped or deformed features of the battery part 600, thebattery part 600 is positioned in the assembly 885 as shown in FIGS. 8Aand 88. More specifically, the battery part 600 is positioned betweenthe first die member 892 and the second die member 886, with the endportion 890 of the core 889 inserted into the battery part 600. At thisstage in the manufacturing, the first deforming surface 894 of the firstdie member 892 contacts the first sealing member 677 a, the seconddeforming surface 887 of the second die member 886 contacts the secondsealing member 677 b, and the third deforming surface 891 of the core889 contacts the extension 683.

In one embodiment, when the first die member 892 drives the battery part600 towards the second die member 886 and the core 889, the firstdeforming surface 894 deforms the edge portion 679 of the first sealingmember 677 a and the second deforming surface 887 deforms the edgeportion 679 of the second sealing member 677 b (as shown in FIGS. 80 and8D). More specifically, when the first die member 892 moves towards thesecond die member 886, the first and second deforming surfaces 894 and887 form an annular groove around the battery part 600 that deflects orotherwise deforms (e.g., plastically deforms) the edge portions 679 ofthe sealing members 677 towards one another. Moreover, the thirddeforming surface 891 of the core 889 simultaneously deforms theextension 683. More specifically, as the core 889 is further insertedinto the battery part 600, the extension 683 deflects or otherwisedeforms (e.g., plastically) along the tapered third deforming surface891. As will be appreciated by those of ordinary skill in the art, thefirst die member 892, the second die member 886, the sleeve 888, and thecore 889 can all be independently movable relative to one another tocrimp or deform the features of the battery part 600 (e.g., the core889, sleeve 888, and/or second die member 886 can independently movetowards the first die member 892). Moreover, as will also be appreciatedby those of ordinary skill in the art, any of the components of theassembly 885 can be sized and/or interchanged with other componentsaccording to the size and specification of the battery part 600.

FIG. 8C is a cross-sectional side view of an assembly 885 after theassembly 885 has crimped or deformed the sealing members 677 and theextension 683 of the battery part 600. FIG. 8D is an enlarged detailview of a portion of the assembly 885 of FIG. 8C. Referring to FIGS. 8Cand 8D together, with the movable components of the assembly 885 in theillustrated dosed or deforming position (e.g., with the first die member892 contacting the second die member 886 and/or the core 889), thesealing members 677 and the extension 683 have been crimped or deformedto provide the sealing and engaging features of these components asdescribed above with reference to FIGS. 6A-7.

The various battery parts described above can be manufactured from lead,lead alloys, and/or other suitable materials known to those of ordinaryskill in the art. In addition, these parts can be manufactured by anysuitable manufacturing method such as die casting, cold forming, dieforming, die bending, roll forming, stamping, forging, machining, etc.For example, in one embodiment, the battery parts described herein canbe formed by cod-forming with a segmented mold, such as a segmented moldhaving two segments. In addition, various embodiments of the batteryparts described herein can be formed in accordance with methodsdisclosed in, and can include features at least generally similar to,those disclosed in U.S. Pat. No. 5,349,840, which is incorporated hereinin its entirety by reference.

From the foregoing, it will be appreciated that specific embodiments ofthe disclosure have been described herein for purposes of illustration,but that various modifications may be made without deviating from thespirit and scope of the various embodiments of the disclosure. Forexample, although many of the Figures described above illustrate batteryparts having cylindrical portions (e.g., cylindrical lug portions, baseportions, through-holes, etc.), in other battery parts configured inaccordance with the present disclosure these portions can have one ormore flat sides and/or other non-cylindrical surfaces. Further, whilevarious advantages associated with certain embodiments of the disclosurehave been described above in the context of those embodiments, otherembodiments may also exhibit such advantages, and not all embodimentsneed necessarily exhibit such advantages to fall within the scope of thedisclosure.

We claim:
 1. A battery part configured to provide a connection for abattery, the battery part comprising: a base portion configured to be atleast partially embedded in battery container material; a lug portionextending from the base portion; a bore aligned with a longitudinal axisextending through the base portion and the lug portion; and a flangeextending outwardly from the base portion, wherein the flange includes:a plurality of first recesses having a first shape, wherein individualfirst recesses have first and second sidewalls oriented at correspondingfirst and second angles that are slanted relative to the longitudinalaxis; and a plurality of second recesses having a second shape differentthan the first shape.
 2. The battery part of claim 1 wherein theplurality of first recesses have an upside-down U-shaped configurationwith openings that extend away from the lug portion.
 3. The battery partof claim 1 wherein at least one of the second recesses has acorresponding third sidewall oriented at a first direction and a fourthsidewall oriented at a second direction substantially perpendicular tothe first direction.
 4. The battery part of claim 1 wherein the secondrecesses are grouped circumferentially into a first group of secondrecesses and a second group of second recesses, wherein the first groupof second recesses is separated circumferentially from the second groupof second recesses by two or more of the first recesses.
 5. The batterypart of claim 1 wherein the first and second sidewalls separated by afirst circumferential distance, and wherein the second recesses comprisethird and fourth sidewalls separated by a second circumferentialdistance different than the first circumferential distance.
 6. Thebattery part of claim 1 wherein the second recesses are grouped into afirst group of second recesses and a second group of second recesses,and wherein first and second groups of second recesses are positioned atradially opposite locations of the flange.
 7. The battery part of claim1 wherein the base portion has a lower surface, wherein the first cavityhas a first diameter proximate the lower surface and a second diameterproximate the second cavity, and wherein the first diameter is greaterthan the second diameter.
 8. The battery part of claim , furthercomprising: a stepped shoulder portion at an interface between the firstand second cavities; and a lip extending from the shoulder portiontoward an interior surface of the first cavity.
 9. The battery part ofclaim 1 wherein the flange is a first flange, further comprising asecond flange spaced apart from the first flange.
 10. The battery partof claim 1, wherein the bore includes: a first cavity having a taperedcylindrical shape extending from the base portion at least partiallyinto the lug portion, and a second cavity having a cylindrical shapeextending from the first cavity through a remainder of the lug portion.11. The battery part of claim 1 wherein the flange is configured to atleast partially prevent the base portion from axially pulling out of thebattery container material.
 12. A battery terminal bushing, comprising:a base portion having a lower surface, wherein the base portion isconfigured to be at least partially embedded in battery containermaterial a lug portion extending from the base portion; a through-holeextending longitudinally through the base portion and the lug portion,wherein the through-hole includes a first hole portion extending fromthe base portion partially into the lug portion, wherein thethrough-hole includes a second hole portion extending from the firsthole portion through a remainder of the lug portion, wherein the firsthole portion has a tapered cylindrical shape having a first diameterproximate the lower surface and a second diameter proximate the secondhole portion, and wherein the first diameter is greater than the seconddiameter; and a torque resisting flange extending outwardly from thebase portion, wherein the torque resisting flange comprises a pluralityof recesses extending radially inward therein, and wherein at least oneof the recesses has an upside-down U-shaped configuration that openstoward the lower surface, and includes a first beveled sidewall oppositea second beveled sidewall.
 13. The battery terminal bushing of claim 12wherein the plurality of recesses include: a plurality of first recesseshaving a first shape, and a plurality of second recesses having a secondshape different than the first shape.
 14. The battery terminal bushingof claim 13 wherein at least one of the second recesses has acorresponding third beveled sidewall oriented at a first direction and afourth beveled sidewall oriented at a second direction substantiallyperpendicular to the first direction.
 15. The battery terminal bushingof claim 13 wherein the second recesses are grouped circumferentiallyinto a first group of second recesses and a second group of secondrecesses, wherein the first group of second recesses is separatedcircumferentially from the second group of second recesses by two ormore of the first recesses.
 16. The battery terminal bushing of claim 13wherein the first and second beveled sidewalls are separated by a firstcircumferential distance, and wherein the second recesses include thirdand fourth beveled sidewalls separated by a second circumferentialdistance different than the first circumferential distance.
 17. Thebattery terminal bushing of claim 13 wherein the second recesses aregrouped into a first group of second recesses and a second group ofsecond recesses, and wherein first and second groups of second recessesare positioned at radially opposite locations of the torque resistingflange.
 18. The battery terminal bushing of claim 12, further comprisinga plurality of grooves extending peripherally around the base portionand positioned axially between the base portion and the torque resistingflange.
 19. The battery terminal bushing of claim 12 wherein the secondhole portion has a cylindrical shape having a diameter substantially thesame as the second diameter.